Molds for making dolls composed of plastic material



Jan- 3, 1956 J. L. KALLUS MOLDS FOR MAKING DOLLS COMPOSED 0F PLASTIC MATERIAL Filed May 22, 1951 V INVENTOR uos H KQLLUS .s ATTORNEY MOLDS F.0RMAKING DQLLs ComosttnoF -BLASTICMATERIAL Joseph 'Lsxanu New'Yorlit, Y. Application .May2 2,1951,;Serial-No. 227,610 3'Claims. (CI. 18-34) This invention relates to molds for n' aking dolls composed of plastic material, such as plastisol or the like, and to the method formaking sne'h molds. 1

Among the objects of the present; invention,-.;it iszaimed 'to provide an improvedmold; for making dolls-composed .0Pt nings to:receive elementspsuch as'eyes, and ,the like. it Q mp0sitions,.suc h 3.811111128111218 an instance, due to the process stepspf forming :such :dolls composed of rubber, it wasnecessary.tojormqthe molds in halves wh a w y Presente ..a.problem;.of removing ,the protrusion or rib at the seam where the mold halves engaged, aside from the extra labor and expense in carrying out such additional step.

Although it has been known to make one-piece doll portions, such as the head member, body member and the like from resilient plastic material, difficulty has heretofore been encountered in securing to the same, eye inserts, and the like. The difiiculty was due primarily to the problem of forming recesses of the desired contour and conformation. To this end, the present invention aims to provide a mold which will facilitate the formation of a one-piece head of a doll composed of a substance such as plastisol and the like, with recesses to accommodate eye inserts, and the like.

These and other features, capabilities and advantages of the present invention will appear from the subjoined detailed description of specific embodiments of the mold constituting an important part of the present invention and also of the parts used to form the mold of the present invention illustrated in the accompanying drawings, in which Fig. 1 is a fragmental sectional view of the head part of a wax model coated with a suitable metal preparatory to the electroplating treatment.

Fig. 2 is a fragmental sectional view of the head part of a mold after the plastic skin has been formed inside of the same, but before the skin has been removed from the mold.

To form the mold constituting the main part of the present invention, it is necessary, see Fig. l, to form a last wax model composed of a readily fusible wax, such as electroplaters wax and then to cover the model with a coat of some metal, such as a solution of silver nitrate conventionally used for electroplating with copper. In Fig. 1. the wax model part 1 is shaped to form a dolls head which is covered with a coating 2 of some metal such as the conventional silver nitrate solution used for electroplating copper. Here attention is particularly called to the recess 3 formed to emulate the eye socket to receive the independent metal part, such as the metal insert 4 which is inserted into the model 1 so that a rib 5 is formed around the insert 4. At the neck there is formed an annular recess 6 in the model 1.

' less.

2,728,947 Patented Jan. 3, 1956 pending upon the thickness desired for the mold walls 13, see Fig. 2, the wax model 1 is retained in the bath a greater or lessperiod of time. When the desired thickness of mold wall 13 has been produced, the model 1 is removed from the bath and then heatedto the temperature desired to melt the wax in the model 1, which melted wax is; then poured out of the mold when the mold 13is ready for use. Preferably,,however, before proceeding to form doll members, it is then desired to cool the mold 13 to a temperature approximately ,F. or If the mold, had previously been made and keptin stock, then it is desired to heat the mold 13 so that it has a temperature of about 100 F. Thereupon a plastic mass is poured into the mold 13. Preferably when the plastic mass has so been introduced into the mold 13, the mold is rocked toand fro, known as slushing in the technique, to enable the plastic mass intimately to contact the entire inner surface of the mold 13. Due to the consistency of the plastic mass, especially when having a temperature of about 70 F., and the mold is approximately 100 'F., a substantial layer 15 of the plastic mass willradhere and cling to the inner face of the mold 13, so that thelexcess can bepoured out. anda substantial layer will remain clinging throughout to the inner wall of the mold 13. Excellent results have been achieved when the plastic mass consists of a mixture of polyvinyl chloride resin, dioctyl phthalate, diisoctyl adipate, and santicizer. After the excess has so been poured out, the mold 13 with its inner layer 15 is heated to a temperature of about 370 F. for about five minutes. Thereupon the mold 13 is removed from the heater and sprayed with water of about 70 F. for about one minute. Thereupon the layer 15 will have been coagulated or cured and be in condition to be stripped, intact, from the inner face of the mold 13.

One of the features of the present invention consists in forming a mold having unusual intricate contours, particularly if the contours include deep crevices or pockets or even elongated pockets. When the mold calls for intricate contours such as are required to form eye sockets, it has been found desirable to insert in the wax model 1 as aforesaid, the metal inserts 4 which may be machine cut to the precise contour required. If the metal inserts 4 are composed of copper or brass, then when the electroplating process ensues, the wall of the mold 13 will unite with the inserts 4, and the inserts 4 will become an integral part, or at least a fixed part, of the mold 13.

In the formation of these skins it was also discovered that an electroplate deposit would not produce a precisely contoured pocket beyond a certain depth. In other words, beyond a certain depth the inner end or bottom of the socket would attract either a very thin deposit as compared to the rest of the mold or else the corners adjacent the bottom would disappear, the sharp corners being filled with deposits so there eventually would appear a slope or incline between the side walls and the bottom of the socket and eliminate any resemblance to the original sharp corner socket such as might be formed between a cylinder and its base. To overcome this difliculty, the inserts 4 were provided to produce the required deep eye sockets.

Excellent results have been achieved when the thickness of the mold wall 13 approximated between .070 and .090 of an inch and the thickness of the skins 15 and 16 3 parting from the general spirit of the invention as set forth in the appended claims.

I claim:

1. A mold for a dolls head having two small chambered spherical eye-forming metal wall portions each having a restricted small opening, and a large chambered head-forming metal wall portion having a restricted main opening at the neck portion of the dolls head and extending into and completely covering the inner faces of the eye-forming wall portions, said large metal wall por-- tion metallically secured to the entire inner faces said small chambered wall portions with its inner face forming the outer conformation of the dolls bead including the face of the dolls head and with the small chambered wall portions extending inwardly from the large chambered metal wall portion and their outer faces forming deep bulging eye sockets in the dolls head.

2. A mold for a dolls head having two small charm bered spherical eye-forming metal wall portions each having a restricted small opening, and a large chambered head-forming metal wall portion having a restricted main opening at the neck portion of the dolls head and extending into and completely covering the inner faces of the eye-forming wall portions, said large metal Wall portion metallically secured to the entire inner faces of said smallchambered wall portions with its inner face forming the outer conformation of the dolls head including the face of the dolls head and with the small chambered wall portions extending inwardly from the large chambered metal wall portion and their outer faces forming deep bulging eye sockets in the dolls head, said small chambered wall portions being preformed, said large chambered metal wall being electrodeposited metal,

. 4 and said electrodeposited metal wall completely filling said small chambered wall portions and united to the entire inner faces of said small chambered wall portions. 3. A mold for a doll's head having two small eye chamber-forming metal portions each having a restricted small opening, and a large chambered head-forming metal wall portion having a restricted main opening at the neck portion of the dolls head and extending into and completely covering the inner faces of'thc eye-forming portions, said large metal wall portion metallically secured to the entire. inner faces of said small chambered portions with its inner face forming the outer conformation of the doils head including the face of the doll's head and with the small chambered portions extending inwardly from the large chambered metal wall portion and their outer faces forming deep bulging eye sockets in the dolls head.

References Cited in the file of this patent V UNITED STATES PATENTS.

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